Jet Mill Microparticle Dry Coating for Inhaler Efficiency
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Solution Overview
Problem
Current dry powder inhalers face low drug delivery efficiency due to drug particle agglomeration and strong cohesive forces, leading to deposition in the throat and upper airways rather than the deep lung, where therapeutic action occurs.
Innovation Solution
A device and method utilizing a jet mill to deaggregate dry powder particles into microparticles with an aerodynamic diameter of less than 5 microns, which are then directed onto a surface using a customized nozzle system to optimize press-on forces for effective coating and aerosolization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dry powder particles are coated onto surfaces using conventional methods, then drug particles can be delivered to surfaces, but strong cohesive forces cause particle agglomeration leading to deposition in throat and upper airways instead of deep lung
Solution Approach 1:
The patent applies segmentation by breaking down drug particles into smaller size ranges (0.5-5 microns) using jet mill technology. This particle size reduction prevents agglomeration and ensures particles can reach the deep lung rather than depositing in the throat and upper airways, directly resolving the harmful agglomeration effect while maintaining delivery efficiency.
Solution Approach 2:
The patent changes the critical parameter of particle aerodynamic diameter to less than 5 microns through jet milling processing. This parameter change transforms the physical properties of drug particles, reducing cohesive forces and preventing agglomeration, thereby enabling effective deep lung delivery while maintaining high productivity.
2Manufacturing precision
If jet mill is used to deaggregate particles into microparticles, then particle size is reduced below 5 microns, but press-on forces during coating may be too strong preventing detachment during inhalation
Solution Approach 1:
The patent optimizes the press-on force parameter during the coating process by controlling jet mill operating conditions and coating parameters. This allows achieving the dual goal of reducing particle size to below 5 microns for deep lung delivery while maintaining press-on forces at levels that allow particle detachment during inhalation, resolving the contradiction between manufacturing precision and force control.
3Ease of manufacture
If conventional coating methods are used, then coating process is simple, but drug-drug cohesive interactions are not effectively eliminated
Solution Approach 1:
The patent replaces conventional mechanical coating methods with jet mill-based fluidization and coating technology. This substitution eliminates the need for complex mechanical coating equipment while effectively breaking drug-drug cohesive interactions through fluidized bed processing and controlled press-on forces, achieving both simplicity and effectiveness.
Solution Approach 2:
The patent uses pneumatic principles in the jet mill system to deaggregate and coat drug particles. Compressed air fluidizes the powder bed and enables controlled particle coating, effectively eliminating drug-drug cohesive interactions without requiring complex mechanical systems, thus maintaining ease of manufacture while removing harmful cohesive forces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly improves the delivery of drug particles to the deep lung by reducing agglomeration and enhancing aerosolization, increasing the respirable fraction of the drug dose and improving the efficiency of dry powder inhalers.
Implementation Method 1
a jet mill configured to mill dry powder particles into microparticles having a desired aerodynamic diameter and to deaggregate the microparticles
Implementation Method 2
a jet mill configured to mill dry powder particles into microparticles having a desired aerodynamic diameter and to deaggregate the microparticles
Implementation Method 3
an exit nozzle associated with the jet mill. The exit nozzle may be arranged to direct deaggregated micronized dry powder particles from the jet mill to the surface to be coated
Implementation Method 4
Research has shown that there is an optimum range for press-on forces during coating; strong enough to adhere the drug to the film surface
Implementation Method 5
the cohesive forces that exist between them, due primarily to Van der Waals and electrostatic forces, are quite strong and prevent drug particles from being readily deaggregated
Implementation Method 6
the cohesive forces that exist between them, due primarily to Van der Waals and electrostatic forces, are quite strong and prevent drug particles from being readily deaggregated
Data Source
AI summary
A device for coating dry powder microparticles onto a surface may include a jet mill configured to mill dry powder particles into microparticles having a desired aerodynamic diameter and to deaggregate the microparticles, a feed hopper structured and arranged to feed dry powder particles to the jet mill, a surface configured to receive dry powder microparticles and an exit nozzle associated with the jet mill. The exit nozzle may be arranged to direct deaggregated micronized dry powder particles from the jet mill to the surface to be coated. The device may further include a holder structured and arranged to hold an item, wherein the item includes the surface. In some aspects of the device, the item may be a film.